Nov 152018

Today, the job was to connect the three rainwater inlet pipelines (from our two roofs) and the output pipe to the Filtration module. But first, a leak test was performed. Sprinkling water (from our garden hose) on to the wall above the seals, we noticed that there were a couple of leaks along the bottom edge. After carefully scraping away the sand and gravel and cleaning the joint, more white sealant was applied and forced it into the joint. All the edges was done to ensure that we don’t have another leak.
Next was connecting the rainwater pipeline coming from the garage which needed a simple right angled turn and head straight into the cabinet. Next was the white pipe (this is the clean water after filtration and supplying our underground tank) but we discovered that we needed a 30° turn to make it head perpendicular into the cabinet and no one sold this angle for 40mm diameter pipes (they had 90° and 45° and straight) but nothing else. so we had to go out and buy a flexible small length of pipe. We glued together the required pieces to form the pipeline to the underground storage tank (under the garage).

Filtration Unit Connected to Pipelines


Finally, the last two rainwater pipelines (from the main house) were connected to the side of the cabinet.
Filtration Unit Connected to Pipelines


All these joints had to have a slip type of connector which allowed the whole straight connector to slide almost fully onto the pipe, move or rotate the assembled pipeline into place and push the slip connector over the both pieces.
The last job tomorrow is to do further water leakage tests and then connect the soak-away pipeline to the back of the cabinet to takeaway overflowing water (on those very rare occasions of a very heavy thunderstorm).

 Posted by at 6:33 pm
Nov 142018

Today, we took the opportunity of a very nice sunny day and that the hole was reasonably dry, to tackle the job of installing and burying our new Rainwater Filtration Module, at the end of the swimming lane. We have had to wait for a few days whilst the rain drained out of the hole (The roof of the garage drains into the hole at the moment – it will connect to the filter soon)

Filtration Module Got Installed!


We started by digging out the hole of the excess material that had slipped in during the rain we had last week and got a wheel barrow load of gravel and sand mixture to provide a good and firm surface. We used our laser site level to make sure the bottom of the hole was set to 1metre below ground level.
Then we built a ramp come platform (made from three 4.8metres 2inch by 4inch planks screwed together using lots of pieces of plywood) and placed it across our hole (the far end supported on the mass wall against the fence and the other end packed on to the dirt pile), ready to take our 140kg cabinet!
We laid the module on the trolley, put on some extra temporary support arms at the top of the cabinet (for connecting lifting straps to the winch motor) and carefully rolled it out of our workshop and around to our ramp.
Filtration Module Got Installed!


After a struggle to get it upright, and then sliding it along the ramp and then trying rope but finally settling on nylon straps to lift it clear. We pulled the ramp away and lowered the whole cabinet down into our hole. After some fiddling around with the straps and the supporting arm plus also tidying up the gravel surface again, we got the thing landed solidly into place at last!
It was getting dark by this time so we got out our flood lights and carried on with drilling the seven fixing holes into the concrete blocks of the swimming lane’s wall and screwing concrete bolts into the back of the cabinet and then covering up the metal work with more polyester resin.
The last job was to secure the vertical side “lid” to enclose and seal the joint with plenty of PU sealant and a couple dozens of screws.
Filtration Module Got Installed!


It was pitch black and tomorrow, we will finish the task of connecting the various pipelines to the new filtration module, including doing a leak test! Phew what a long day it was today!!

 Posted by at 7:31 pm
Nov 102018

This report is a summary of our week’s worth of work we did on our rainwater Filtration Module. Most of the time was spent on creating the two filter units and two baffles. The flat one had the wire mesh welded onto a heavy metal framework and then coated in several layers of resin to prevent rusting. The second filter unit is a square box shaped, made with just more of the same wire mesh and this was also coated in resin too. Our geotextile material was delivered and we cut and shaped the material into each of these two filters. The flat one had extra padding tied onto the metal edge to provide a soft conforming interface and reduce any leaks. The outer layer was then stitched into place with fishing line.

Another Week On Filtration Module and All Done At Last!


Another Week On Filtration Module and All Done At Last!


The box filter had the same cloth material wrapped up the inside and folded into the flange edging and coated in several layers of resin to reinforce it and lock the cloth into place.

Then we made two baffles, which are like flat tea tray like objects, about 400mm (15inches) wide and 580 (22inches) long, with upwards edges approximately 25mm high. We used some more wire mesh and laid two layers of the glass fibre matting (one on the underside of the mesh and the second one inside the tray) and all coated in resin. We had to bend up several tags over the tray so it can support its sibling companion tray on top, and the top tray having water deflectors to help slow down the rainwater rushing into the cabinet.

Finally, we did some minor adjustments inside the main cabinet, mostly in the area of the clean water filter, near the bottom portion.

Another job we did this week was the installation of the Return Channel vertical module to the end of the Swimming Lane. It was a lovely day so we took the opportunity to get that done while we remembered it before we tackled the big job of getting the main cabinet installed.

Another Week On Filtration Module and All Done At Last!


Now we just need another moment like this to haul the large heavy module into place.

 Posted by at 6:11 pm
Nov 052018

Today, we continued with the task of building our two water filters. The long flat one’s frame is now constructed with a heavy thick metal bar around the perimeter and the metal mesh is welded on to it.

Water Filters Progresses


Water Filters Progresses


Water Filters Progresses


The second filter, the box shaped one, was tidied up, removing excess mesh material and it is now ready for the cloth geotextile fabric to be folded and inserted in.
Water Filters Progresses


Hopefully, tomorrow, we will get our new piece of the geotextile fabric (coming in the post) and we can wrap these two skeleton frameworks and then paint the metalwork in protective resin to stop rusting and also seal and hold the cloth in place.

 Posted by at 5:55 pm
Nov 042018

We constructed a small test rig, to reflect the design and placement of the two layers of the wooden battens to be on our roof and then played with a dozen slate tiles.

Trial Run in Working with our Slate Tiles


Trial Run in Working with our Slate Tiles


The first row of any roof has to have two tiles (the lower tile is cut down in height) to ensure that the rainwater will be directed down the slate and not drip through onto the battens and the breathable membrane. We tested using the copper nails (through two holes) to see how they work, and tested using the hook nails (a bent rod of metal running underneath and hooks on the bottom edge)
Trial Run in Working with our Slate Tiles


It is quite obvious that there is a need for a “filler” to be inserted on the first batten, to take the place of the missing third tile, so we will fold up our gutter metal mesh guard several times to the required thickness and when that is nailed on the first batten row, that will provide the extra height needed.
The overhang distance of the bottom edge of the slate tiles will be about 55mm so we will position the first line of battens so that the tiles will hang over the gutters by 25mm, and the rainwater drips nicely in.

 Posted by at 4:48 pm
Nov 032018

This is a combined report showing our progress of creating our rain water filtration module. It has been a very fiddly work, constrained by the slow “drying” time of the polyester resin substance, but also having to take time and care to prepare, tidy-up and adjust the glass-fibre surfaces after each application of the resin. It is a slow job.
But we can report that we are nearly there now, with the completion of all the “lids”, the swimming lane Return channel unit and much of the main cabinet, all coated in the final top-coat light grey coating.

Six Days on Water Filter Cabinet, Almost There!


Six Days on Water Filter Cabinet, Almost There!


Today, we started designing and producing two filters, the first one designed (in a box like shape) to tackle the initial very dirty flush of rain water collected off the roofs and the second one, being a long flat slope for providing a final filter to ensure minimal particles of “rubbish” doesn’t get into our rainwater storage tank.
Six Days on Water Filter Cabinet, Almost There!


Six Days on Water Filter Cabinet, Almost There!


These are made from heavy-duty weld mesh, supporting some geotextile fabric, mounted with a reinforced metal rim and the rim coated in protective resin.
We needed to make these filters now so we could confirm that everything fits into place, so we will achieve the correct flow of the water and that we could successfully remove and put back them via the proper entrance (the top of the cabinet). Just in case we needed to make further adjustments to the internal layout, as we did exactly this the other day (the long sloping filter didn’t come down low enough and would have held quite a bit of rainwater back in the pipes running from the buildings), before we applied the final light grey top-coat.. Also, it is only sensible to make sure that we design and make these filters and baffles here and now (in the workshop) so we can test the created products before we close up the filter and make it much harder to test things.

So on Monday and Tuesday, we will complete these final bits and pieces and then tackle the next problem of transporting this heavy unit and installing it into our flooded hole in the ground – We had lots of rain these last few days!! But the next week look drier so the hole should hopefully dry up!

 Posted by at 6:35 pm
Oct 312018

Sometime during the afternoon, we had the delivery of the remaining four pallets of our slates and they were unloaded alongside our Loke, following the line as we intended, but alas, one of the pallets was dumped on top of two others!

The Last Four Pallets of Slates Arrive


We did not want this, as we wanted to be able to take a handful of tiles out from each crate in turn so the roof would get a more random pattern, just in case, one crate would be loaded in the quarry from one spot in the slate mine and by the eleventh crate, could be using another part of the mine with slightly different colouration and texture. Hence, as recommended by experts, to take a few tiles from every crate, to mix it up a bit, and get a more balanced finished on our roof.

 Posted by at 6:00 pm
Oct 312018

This morning, under the bright hot sun, we went on the roof of our Store Room to locate the leaks we had yesterday during a day of heavy rain. We found them and applied pieces of flashing tape, by using a hot air gun to dry the roofing felt and also warmed up the flashing tape too and rolled it hard into the surface.

Fixed Small Patches of Damage on Store Room Roof


Fixed Small Patches of Damage on Store Room Roof


We did several more patches on other parts of the roof, one definite hole but several were potentials so they got patched too.
Now we wait until the next rain storm and see if we have found all the sources of our leaks!

 Posted by at 11:45 am
Oct 292018

We had a delivery of the remaining timber battens, 720 metres of 38mm by 25mm sized lengths, but actually, we only got 714 metres so they short-changed us by 6 metres (but we did get extra of the larger battens) !

First Batch of Slates Arrive


We now have all our wooden battens, ready for our roof.

We also had the first batch of our Slates , seven pallets, in total, containing over eleven thousand standard sized and 750 extra wide ones.

First Batch of Slates Arrive


First Batch of Slates Arrive


Each pallet has over 1800 slates in 3 layers. We are expecting a further four more pallets of standard size in a few days.

 Posted by at 10:27 am
Oct 272018

We resumed the task of coating the filtration unit in the structural layer of glass-fibre, in doing the exterior of our large filter box.

Exterior of Filter Module Coated in Glass-Fibre and Cleaning up Other Pieces


Then the rest of the day was spent cleaning up all the other pieces, trimming excess glass-fibre sticking out and sanding down rough patches and edges. We did one small experiment to find out how we can coat the final exposed edges, by using four layers of glass-fibre tissue cut into strips and then painted onto the flat top and bending it around and down the two sides. It seemed to have worked but we will inspect tomorrow or Monday.

We are nearly finished doing this stage of work and all is left to do is to apply the top “finishing” coat to provide the smooth glossy surface inside and out. Then we just need to chuck it into the hole in the ground, connect up the pipes .. and hey presto – that is that – grin!

 Posted by at 6:02 pm